Electrical connection pin assembly

Abstract

An electrical connection pin assembly for use in a subsea environment includes a pin tip having a main body and one of a sheath and a core that extends along a centerline. The pin tip is formed from a corrosive resistant material and a main conductor includes the other of the sheath and the core. The core is disposed within the sheath, and the main conductor is formed from an electrically conductive material that is different from the corrosive resistant material. A crimped joint is formed between the core and the sheath to electrically and mechanically attach the main conductor to the pin tip, and an insulating layer is formed to sealably cover a portion of the core and a portion of the sheath.

What is claimed is: 
     
         1 . An electrical connection pin assembly for use in a subsea environment, the pin assembly comprising:
 a pin tip having a main body and one of a sheath and a core that extends along a centerline, the pin tip formed from a corrosive resistant material;   a main conductor including the other of the sheath and the core, the core disposed within the sheath, the main conductor formed from an electrically conductive material that is different from the corrosive resistant material;   a crimped joint formed between the core and the sheath to electrically and mechanically attach the main conductor to the pin tip; and   an insulating layer formed to sealably cover a portion of the core and a portion of the sheath.   
     
     
         2 . An electrical connection pin assembly as claimed in  claim 1 , wherein the corrosive resistant material includes one of gold, silver, nickel, molybdenum, titanium, and chrome in elemental or alloy form. 
     
     
         3 . An electrical connection pin assembly as claimed in  claim 2 , wherein the electrically conductive material is formed from one of copper, aluminum, a copper alloy, and an aluminum alloy. 
     
     
         4 . An electrical connection pin assembly as claimed in  claim 1  wherein the insulating layer covers the sheath. 
     
     
         5 . An electrical connection pin assembly as claimed in  claim 1  wherein the sheath defines a hollow portion sized to receive the core. 
     
     
         6 . An electrical connection pin assembly as claimed in  claim 1  wherein the pin tip includes the sheath, and the main conductor includes the core. 
     
     
         7 . An electrical connection pin assembly as claimed in  claim 1  wherein the pin tip includes the core, and the main conductor includes the sheath. 
     
     
         8 . An electrical connection pin assembly as claimed in  claim 1 , wherein the electrically conductive material has an electrical resistivity that is lower than the electrical resistivity of the corrosion resistant material. 
     
     
         9 . An electrical connection pin assembly as claimed in  claim 1  wherein the corrosion resistant material has a pitting resistance equivalent number greater than 32. 
     
     
         10 . An electrical connection pin assembly as claimed in  claim 1  wherein the corrosion resistant material has a pitting resistance equivalent number greater than 40. 
     
     
         11 . An electrical connection pin assembly as claimed in  claim 1  wherein the pin tip includes one of the group including Inconel®, Monel®, Super Duplex®, or a nickel-based alloy. 
     
     
         12 . An electrical connection pin assembly as claimed in  claim 1  wherein the pin tip is formed from material that has an electrical resistance greater than the material that forms the main conductor. 
     
     
         13 . An electrical connection pin assembly as claimed in  claim 1  wherein the main conductor is formed from material that has an electrical resistance less than 5E-08 Ohm·m. 
     
     
         14 . A method of forming an electrical connection pin assembly for use in a subsea environment, the method comprising:
 forming a pin tip from a corrosive resistant material, the pin tip including a main body and one of a sheath and a core that extends along a centerline;   forming a main conductor from an electrically conductive material, the main conductor including the other of the sheath and the core;   positioning the sheath to surround a portion of the core;   compressing the sheath against the core to form a crimped joint; and   overmolding an insulating layer onto a portion of the core and a portion of the sheath to sealably enclose an interface between the sheath and the core and inhibit contact between water in the subsea environment and the interface.   
     
     
         15 . A method of manufacturing an electrical connection pin assembly as claimed in  claim 14 , wherein the pin tip includes the sheath and the main conductor includes the core. 
     
     
         16 . A method of manufacturing an electrical connection pin assembly as claimed in  claim 14 , wherein the electrically conductive material includes one of copper, aluminum, a copper alloy, and aluminum alloy. 
     
     
         17 . A method of manufacturing an electrical connection pin assembly as claimed in  claim 14 , wherein the corrosive resistant material includes one of gold, silver, nickel, titanium, and chrome in elemental or alloy form. 
     
     
         18 . A method of manufacturing an electrical connection pin assembly as claimed in  claim 14 , further comprising machining the insulating layer to remove a portion of the insulating layer to achieve a desired dimension of the insulating layer. 
     
     
         19 . A method of manufacturing an electrical connection pin assembly as claimed in  claim 14  wherein the method further comprises the step of machining each of the pin tip and the insulating layer to a desired dimension. 
     
     
         20 . A method of manufacturing an electrical connection pin assembly as claimed in  claim 14 , further comprising selecting an electrically conductive material that has an electrical resistivity that is lower than the electrical resistivity of the corrosion resistant material.